Hollow-slab building structure.



v 1. T. CARROLL. HOLLOW SLAB BUlLDlNG STRUCTURE.

APPLICATION FILED OCT-.3. l9! 7.

Patented Aug. 6, 1918,

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WITNESSES v ATTORNEYS JAME$ r, cannon, or mnnmcs, monrmnl I-IOLLOW-SLAB'BUILDING STRUCTURE.

' Specification of Letters lfatent.

' Applicatipn filed October 5, 1917. Serial No. 195,396.

To an 'w/wm, at may concern:

Be it known that I, JAMEs T-. CARROLL, acitizen of the United States, and a resident of Billings,in the county of Yellowstone and State of Montana, have invented a new'and Improved Hollow-Slab Building Structure, of which the following is a full,

clear, and exact description.

This invention relates to concrete or cement gypsum buildings and has to deal more particularly with a novel construction of floor, wall, ceiling, roof or partition islab I and the method of making the same.

manner, and so constructed that the buildmol gives a pleasing appearance to'the outside to suit the builders taste.

ing structure made therefrom will have the advantage of being-fireproof and practically indestructible, the walls, floors and ceilings beingprovided with a large dead air space which guards against-the extremes of cold and heat and against moisture; and the slabsbein of plastic material permit of artistic and forms being employed, which.

of the building, and furthermore, the outer and inner layers of the slab may be tlnted A more specific obJect of the'invention is the provisionof a hollow slab for the uses mentioned which has its air space made by the use of a sand core which is removed by being washed out under the action of a stream of water, the edges of the slab being =closed at all points except that a plurality molded therein and theouter surfaces of 7 I 'With suchobjects in view, and others ceeds; th

of openings are provided for the sand to be washed out, and furthermore, the slabshave integral or metal tie members 'for uniting the o posite faces of the slab, and the faces may reinforced by embedded expanded metal or the equivalent, or by I or other beams, and the slabs for the w'alls-of the building- 'will have door'or window frames walls or of roof slabs may be molded .to

represent blocks, boards, shinglesg 'tile, or p p H a "supp emen a m d s sl v n-thecon e,

"which mold, is employed for forming the sand core 0... This supplemental; moldtis' anyxotlier finish. I

which will appear as the description pro- "uention comprise yamous novel wit m q Pd;

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scammof parts which will be set forth withparticularlty in the following description and claims appended hereto.

Patented ne 5,1918;

In the accompanying drawings, which illustrate one embodiment of the invention midwherein similar character-sol reference indicate corresponding parts in all the views,

' Figure 1 is a vertical section of a building employing the improved slabs-"the section being taken on the line 1+1, Fig. 2;

Fig. 2 is a side view of the bui ding with a'portion in section on the line 22, Fig. l; a v Fig. 3 1s a detail sectional View on the line v33, Fig. 2, to show a doorsill construction;

Fig. 4 is a plan view of the mold with a slab partially formed therein, which slab constitutes a wall of a room andhas a door opening cast therein; v I

, Fig. 5 is a detail sectional view on'the line 55, Fig. 4', showing the slab partially formed in the mold; l Fig. 6 is a similar view showingthe slab completely formed but before it is removed from the mold and the sand core washed line 7-7, Fig.4; and i Fig. 7 is a detail secti nal view on the Fig. 8 isa sectional view of a mold adapt ed for making a slab having reinforcing beams. f l

In connection with Figs. 4. to 8 of the drawings the construction of the slab will be described. The slabs are preferably rectangular with the edge or side surfaces at right-angles to the faces of the slab. The mold for casting the slab com rises a bottom plate 1 which may have. a suitable molding pallet 2 placed thereon to give the outer or inner surface of the slab any desired surface shape to imitate any kind of wall surface,- and suitably fastened to the bottom plate 1 are side walls 3. Into this mold is placed a layer of cementor concrete a as shown in Figs. 5 and 7, and if. it is desired to b11111 thefslah an initial layer-of tinted concrete 4 will be first supplied to themold." After the first layer and before-the concrete isset a form of m old'will follow along the door opening form or mold which rests on the. bottom plate 1. After the core form or mold 5 is set in place moist sand is filled into this form and firmly tamped. Metal tie members 7 having their ends formed into anchors 8 are passed through'the sand core and embedded a few inches in the layer 4 with the upper ends of these, tie elements projecting above the sand core. If desired," small blocks 9 may be embedded in the sand core, which blocks upon being removed provide passages in the sand core so that when the top layer of concrete is applied there will be integ-ral bonds 6 of concrete extending across the air chamber. After the sand core is made the form 5 is removed and a layer of concrete l0 isplaced on the layer 9; while the latter is still soft. Before the layer 10- is filled in' the space around the sand core a plurality of blocks 11 are interposed between the sand core and the outer wall of the mold, these blocks being in the fintc the mold to cover the sand core and the layer 10. In other words, the space in the top of the mold shown in Figs. 5 and 7 is filled with concrete. The several layers of the concrete may be tamped or the slab maybe, compressed in a suitable power press, so "the advantages of the construction an that the slab will be solid at every point anddevoid of air holes. Y

Before the concrete sets wooden blocks 13 may he forced into the surface thereof, as shown in Fig.

' 6, so that picture rail strips can be nailed to the wall'slab. If desired, expanded metal athing or other reinforcing elements 14,

lEFig 8, may be embedded in the first and 7 these recesses being formed by blocks 20 set in the mold, and the recesses provide for hoisting chains being applied around the slabs so that by the use of a derrick the slab can be set up into the proper place without the chain interfering, and when the slab is properly set up the chains can be readily detached by being pulled through the re without requiring any special and the molds or forms removed the sand v is washed out by directing a high pressure stream of water into an opening 12, whereby the slab will have a closed air space or chamber 21, Figs. 1, 2 and 3, which air space will be crossed by the tie elements 7 and b.

At window openings the wall slab will have a window frame 22, Fig. 2, integral. I with the outer and inner walls of the air.

chamber 21, and in the window frame will be embedded sections of tubular tile 23 or the equivalent to form passages for the sash weight cords 24, there being guide rollers 25 for the cords, and the sash weights 26 will i I move up and down in the ai'r chamber 21 ide' boxes. The "foundation of the bui ding hasxits walls slightly wider than the walls B of the building,so that ledges 27 will be formed to enable the edges of the floor slabs C to rest thereon. The ceiling slab D rests onthe top of the w-all'slabs B, and the roof slabs E are molded with seats or shoulders 28 to engage with the ceiling'slab. The lower edges of the roof slabs are molded with imitation rafters'29 to complete the single roof effect.

The roof slabs are tied together by any suit- I 32 clamped between the top edges ofthe roof slabs.

From the foregoingdescription taken in connection with the accompanying drawing?i method of operationf'will be readily understood'by those skilled in the art to which the invention appertains, and while I have described the principle of operation, together with the structure which I now consider to material in a mold, setting a form on the plastic materialwith the form spaced from the walls of the mold, producing a sand core 1n the form, removing the form, applying a passage-forming block between the sand core and a wall of the mold, completing the filling of the mold and covering the sand corewith plastic material, removing the mold and also the passive-forming block, and

washing" out the san core.

2. The herein-described method of make mg a slab with an air chamber, which con- 65 cesses. After the concrete of the slab is set sists in placing a layer of plastic material in a mold, setting up a forin on the said layer, makin a sand core in the said --fo1'm,'

placing tie e ements through the sand core" with their lower ends embedded in the layer 5 of plastic material and their upper ends projecting out of the core, removing the form, placing one or more passage-forming ele 8 ments between the send core and 5, wall of the mold, completing the filling of the mold with plastic material, removing the mold 10 and the passage forming :lelemenqs and washing out the 00m MES 

